Unitary cartridge for particle processing

ABSTRACT

A single disposable cartridge for performing a process on a particle, such as particle sorting, encapsulates all fluid contact surfaces in the cartridge for use with microfluidic particle processing technology. The cartridge interfaces with an operating system for effecting particle processing. The encapsulation of the fluid contact surfaces insures, improves or promotes operator isolation and/or product isolation. The cartridge may employ any suitable technique for processing particles.

RELATED APPLICATIONS

This application is a continuation of and claims the benefit of priorityto U.S. patent application Ser. No. 15/818,333, filed Nov. 20, 2017,which is a continuation of and claims the benefit of priority to U.S.patent application Ser. No. 14/179,760, filed on Feb. 13, 2014 and nowU.S. Pat. No. 9,823,252, which is a continuation of and claims thebenefit of priority to U.S. patent application Ser. No. 13/240,521,filed on Sep. 22, 2011 and now U.S. Pat. No. 8,679,422, which is acontinuation of and claims the benefit of priority to U.S. patentapplication Ser. No. 11/295,183, filed on Dec. 5, 2005 and now U.S. Pat.No. 8,277,764, which claims the benefit of priority to U.S. ProvisionalPatent Application Ser. No. 60/633,396, filed Dec. 3, 2004, the contentsof all above applications being herein incorporated by reference intheir entireties.

FIELD OF THE INVENTION

The invention relates to a method and apparatus for processingparticles, such as a method an apparatus for sorting particles based onpredetermined characteristics.

BACKGROUND OF THE INVENTION

Conventional systems for processing particles rely on a number ofseparate, unintegrated components that are separately manufactured andassembled on site. Such conventional systems are unwieldy, and maysuffer from potential contamination problems.

For example, in conventional particle sorting systems, the particles orcells to be sorted are suspended (the suspension) in a liquid mediumthat passes through a collection of reservoirs, tubes, chambers,nozzles, and/or fittings (collectively referred to herein as “fluidcontact surfaces”). In conventional high-speed optical sorters, thesuspension passes through a nozzle and is formed into a stream ofdroplets (the aerosol phase) before being captured in destinationchambers. That droplet stream (aerosol) touches or contaminates any areawithin the system that is not explicitly sealed away from the stream, asit is difficult to otherwise guarantee that stray or improperly formedaerosol will not spatter in all directions. For this purpose allsurfaces that are not explicitly sealed off from the aerosol phase areconsidered part of the “fluid contact surfaces.”

In many applications that employ particle sorting and other particleprocessing, in particular clinical applications or pre-clinicalresearch, it is important to ensure “operator isolation” and/or “productisolation”. Operator isolation refers to protecting the operator fromexposure to the particle suspension, for example, when there is apossibility of infectious disease agents existing within the suspension.Product isolation refers to isolation of the suspension fromcontamination with traces from outside the suspension, includingcontamination from the environment or from prior suspensions that havepassed through the sorting system.

Conventional sorting systems and other particle processing systemsrequire operation in sealed environmental chambers to provide operatorisolation. However, these types of systems are difficult to service withmanual operations. Conventional systems require either replacement orcleaning of all of the fluid contact surfaces in order to guaranteeproduct isolation and the manual steps required to dismantle, clean, orreplace conventional fluid contact surfaces represent a risk of breakingoperator isolation.

SUMMARY OF THE INVENTION

The present invention provides a single disposable cartridge forperforming a process on a particle, such as particle sorting, thatencapsulates all fluid contact surfaces for use with microfluidicparticle processing technology. The encapsulation of the fluid contactsurfaces insures, improves or promotes operator isolation and/or productisolation. The cartridge may employ any suitable technique forprocessing particles.

According to a first aspect of the invention, a unitary particleprocessing cartridge for performing a process on a sample comprises aunitary particle processing cartridge having formed thereon a particleprocessing component for processing a sample and a plurality of fluidcontact surfaces encapsulated in the unitary particle processingcartridge. All fluid contact surfaces in the unitary particle processingcartridge are encapsulated and sealed from an exterior environment.

According to another aspect of the invention, a particle sorting systemcomprises a unitary cartridge having formed thereon a particle sortingcomponent, a particle source upstream of the particle sorting componentfor providing particles to be sorted to the particle sorting component,a sheath fluid reservoir for providing sheath fluid to suspend theparticles and a keep chamber downstream of the particle sortingcomponent for collecting sorted particles.

According to still another aspect of the invention, a method ofprocessing a sample, comprises the steps of inserting a unitary particleprocessing cartridge in an operating machine and instructing theoperating machine to perform a process on a sample sealed within theunitary particle processing cartridge.

In another aspect, a particle processing system comprises a particleprocessing chip comprising a plurality of microchannels and processingmeans for performing parallel processes on a plurality of samples, acartridge containing a plurality of chambers and fluid paths forproviding and receiving substances to and from the particle processingchip, a holder for mounting the particle processing chip to thecartridge to place the chambers and fluid paths of the cartridge influid communication with the microchannels and a plurality ofaggregating tubes for receiving and aggregating processed samples fromthe microchannels.

In still another aspect, a unitary particle processing cartridge forperforming a process on a sample comprises a unitary particle processingcartridge having formed thereon: a particle processing component forprocessing a sample, a plurality of fluid contact surfaces, comprisingat least one fluid chamber and at least one fluid path, encapsulated inthe unitary particle processing cartridge, wherein all fluid contactsurfaces in the unitary particle processing cartridge are encapsulatedand sealed from an exterior environment and chemical reagents forperforming a process on the sample stored in a chamber of the cartridge.

According to another aspect of the invention, a unitary particleprocessing cartridge for performing a process on a sample is provided,comprising a unitary particle processing cartridge having formedthereon: a particle processing component for processing a sample; aplurality of fluid contact surfaces, comprising at least one fluidchamber and at least one fluid path, encapsulated in the unitaryparticle processing cartridge, wherein all fluid contact surfaces in theunitary particle processing cartridge are encapsulated and sealed froman exterior environment; and beads used for performing a bead-baseddepletion or detection on the sample, wherein the beads are stored in afirst chamber of the cartridge.

In yet another aspect of the invention, a method of processing a sampleis provided. The method comprises the steps of providing a sealedunitary particle processing cartridge and taking the sealed unitaryparticle processing cartridge to a biosafety hood, where the sealedunitary particle processing cartridge is loaded with a sample to beprocessed and a processing means for performing a process on the sample.Then, the sealed unitary particle processing cartridge is inserted in anoperating machine. The operating machine is operated to effectprocessing of a sample sealed within the unitary particle processingcartridge using the processing means. Then, the sealed unitary particleprocessing cartridge is removed from the operating machine, and, in abiosafety hood, processed sample is removed from the sealed unitaryparticle processing cartridge.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates a particle sorting system of the prior art.

FIG. 2 illustrates a unitary cartridge for particle processing accordingto an illustrative embodiment of the invention.

FIG. 3 illustrates a unitary cartridge for particle sorting according toan illustrative embodiment of the invention.

FIG. 4 illustrates a unitary particle sorting cartridge of an embodimentof the invention including an aggregation filter.

FIG. 5 illustrates a unitary particle sorting cartridge of anotherembodiment of the invention including pumps and filters for controllingliquid level and/or the concentration of sheath fluid, as well asproviding sheath recycling.

FIGS. 6A-6D are CAD drawings of an embodiment of a unitary cartridge forparticle processing.

FIG. 7 illustrates an embodiment of a unitary particle processingcartridge of still another embodiment of the invention including a trapfilter for filtering a recycling line from a recycle reservoir.

FIG. 8 illustrates another embodiment of a unitary particle processingcartridge according to the invention, including a pump-based supernatantrecycling component.

FIG. 9 illustrates a unitary particle processing cartridge of stillanother embodiment of the invention, including a pump-based supernatantrecycling component.

FIG. 10 illustrates a unitary particle processing cartridge including apneumatic supernatant recycling system using a hollow core filter and nopumps.

FIGS. 11A-11C illustrate unitary particle processing cartridgeintegrated with a multiwell plate according to one application of theinvention.

FIGS. 12A-12D are photographs of a prototype of a unitary particleprocessing cartridge of an illustrative embodiment of the invention.

FIG. 13 illustrates another application of a unitary particle processingcartridge for processing particles, where the cartridge system allowsfor aggregation of a processed sample off-chip.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a unitary cartridge for performingparticle processing, including particle sorting, on a sample. Thepresent invention will be described below relative to illustrativeembodiments. Those skilled in the art will appreciate that the presentinvention may be implemented in a number of different applications andembodiments and is not specifically limited in its application to theparticular embodiments depicted herein.

As used herein, a “cartridge” refers to a collection of chambers and/orfluid pathways that are linked together as a single, unitary object thatcan be transported or moved as one piece. At least some of thecomponents, such as chambers, in a cartridge may be rigidly linked,while other components, such as channels or tubes connecting chambers,may be flexibly linked.

As used herein, the term “microfluidic” refers to a system or device forhandling, processing, ejecting and/or analyzing a fluid sample includingat least one channel having microscale dimensions. The term “channel” asused herein refers to a pathway formed in or through a medium thatallows for movement of fluids, such as liquids and gases. The term“microchannel” refers to a channel preferably formed in a microfluidicsystem or device having cross-sectional dimensions in the range betweenabout 1.0 μm and about 250 μm, preferably between about 25 μm and about150 μm and most preferably between about 50 μm and about 100 μm. One ofordinary skill in the art will be able to determine an appropriatevolume and length of the microchannel. The ranges are intended toinclude the above-recited values as upper or lower limits. Themicrochannel can have any selected shape or arrangement, examples ofwhich include a linear or non-linear configuration and a U-shapedconfiguration.

FIG. 1 is a general schematic of fluidic contact surface systems in aconventional particle sorting system of the prior art. As shown, aconventional system 10 includes a cell source 12 and a reservoir ofsheath fluid 14, which are used to establish a well behaved core flow ofsuspended particles. Tubes 16, 18 connect the cell source 12 and sheathchambers 14 to a sorting nozzle 20. An aerosol phase region 22 ofdroplets is produced by the sorting nozzle 20, followed by one or morecapture chambers 24 a, 24 b (labeled keep1 or keep2), into whichselected subsets of cells or particles are directed.

In the conventional sorting system 10 of FIG. 1, fluidic contactsurfaces include at least seven different components, as well as allsurfaces contiguous to the aerosol phase region 22, because droplets canspatter in all directions during initiation of flow or flow blockageevents. Of necessity, in this type of conventional system 10, the “keep”chambers 24 a, 24 b must be open chambers in order to be accessible todroplets. The open chambers may introduce or increate contamination orexpose an operator to the material within the chambers. Fluid may bedriven out of the cell source 12 and sheath reservoir 14 using apneumatic (gas) pressure applied through an external port (not shown) onthose reservoirs. The pressure port can be locked by sterile filters,which present additional objects to be cleaned or disposed.

The components of the conventional sorting system 10 are typicallyseparately movable elements that are not sealed from each other or theenvironment. Nor are the separate components built on the samesubstrate.

Throughout the application, similar components of different embodimentsof the unitary particle processing cartridge may be designated with likereference numbers.

FIG. 2 illustrates a particle processing cartridge 100 for performing aprocess on a sample, having many, and preferably all, fluid contactsurfaces encapsulated according to an illustrative embodiment of theinvention. The illustrative unitary particle processing cartridge 100can be designed to perform any suitable process or multiple processes ona sample. Preferably, the unitary particle processing cartridge performsa microfluidic process on a sample. The cartridge may contain one ormore particle processing subsystems 110 enabling one or more unitprocesses to be applied to a sample, such as a suspension, loaded intothe cartridge 100. The particle processing subsystem 110 may beseparately inserted into and removable from the cartridge 100, or may beintegrally formed on the cartridge substrate. For example, the cartridgesubstrate may have formed therein a recess or chamber for receiving theparticle processing subsystem 110. Some examples of unit processes thatmay be incorporated into a unitary cartridge 100 include, but are notlimited to, incubation or staining of particles, washing of particles,including variants where supernatant is purified, heating or cooling ofparticles in a suspension, mixing cells or other particles withchemicals or beads, size-based filtering of particles, depletion orenhancement of a subset of particles in the suspension, sorting ofparticles, and other suitable processes known in the art.

Ideally, in order to prepare particles, such as cells for research orclinical applications, using a unitary cartridge 100 of the illustrativeembodiment of the invention, a user loads the “source”, such as a cellsuspension, into the cartridge via a sample input port 102, operates thecartridge using the processing subsystem 110 and extracts the finalproduct in as finished a condition as possible via a processed sampleoutput port 106. If a processing means, such as a sheath fluid,solution, mixing suspension, magnetic beads and so on, is necessary, theprocessing means may be loaded into the cartridge 100 via a processorinput port 104 and stored in a processing means source 114.Alternatively, a single port can serve as both the sample input port andthe processor input port. An extraction port 108 may be used to accessbyproducts of the processing subsystem 110.

A plurality of chambers disposed between the ports and the subsystem 110may also be provided. Preferably, at least some of the chambers arerigidly connected to each other to form the unitary cartridge 100. Asshown, the illustrative cartridge 110 includes a sample input chamber112 for storing a sample to be processed, which may be provided by thesample input port 102. The sample input chamber 112 is in fluidcommunication with the processing subsystem 110 via a fluid path 116. Aprocessing means input chamber 114 may store a processing means providedvia processor input port 104. A fluid path 118 fluidly connects theprocessing means input chamber 112 to the particle processing component110. A processed sample chamber, illustrated as “keep” chamber 124 a,stores a sample processed by the processing subsystem 110, and may befluidly connected to the particle processing component 110 via a fluidpath 126. A sample output port, such as extraction port 106 may be usedto retrieve the sample from the processed sample chamber. A byproductoutput chamber, illustrated as a “keep” chamber 124 b, may store abyproduct of the process performed using the subsystem, such asunselected particles in a sorting system, or a byproduct solution foranother process, which may be provided to the byproduct output chamber124 b from the particle processing component 110 using another fluidpath 128. A plurality of pneumatic ports 101, 103, 105 and 107 incommunication with the fluid paths applies pressure to facilitate fluidflow through the cartridge. In addition, a plurality of additionalports, chambers and fluid paths may be provided in the cartridge,depending on the type of process performed.

A variety of processes may be performed using the unitary cartridge 100of the illustrative embodiment of the invention. For example, a unitaryparticle processing cartridge of an illustrative embodiment of theinvention may be used to perform incubation or staining of particles.For example, in one application using the unitary particle processingcartridge, suspensions may be mixed and incubated with solutionscontaining fluorophore-labeled anti-CD4 mouse-antibodies in order toselectively label cells expressing CD4 on their surfaces.

In another application, the unitary particle processing cartridge 100may be used for washing of particles in a suspension, including variantswhere supernatant is purified. For example, after the incubation, asdescribed above, it may be desirable to remove unbound antibodies sothat unbound fluorophore does not interfere with optical means foridentifying the CD4 positive cells. Washing of particles in a suspensioncan be done in the unitary particle processing cartridge 100 by pumpingthe suspension from an initial chamber through a filter to separate thecells from the supernatant. Then, the extracted cells may be passed backinto the original chamber, while the supernatant is passed throughanother chamber in the cartridge containing bound protein A oranti-mouse antibodies to precipitate any antibodies remaining in thesupernatant before the purified supernatant is added back to theoriginal chamber. This process can continue to cycle through thecartridge until the unbound antibody has been adequately removed fromthe supernatant.

In another application, the unitary particle processing cartridge 100may perform heating and/or cooling of a suspension loaded therein. Forexample, an operating machine may provide heating and/or cooling pads orregions to the cartridge, so that each chamber or region of thecartridge may be held at different temperatures or have its temperaturemodified during operation of the unitary particle processing cartridge.Any suitable means for controlling the temperature within a selectedchamber or region of the unitary particle processing cartridge may beused.

In another application, the unitary particle processing cartridge 100may perform mixing of particles, such as cells, with chemicals, beads oranother substance. For example, a cell suspension in a first chamber ofthe cartridge 100 may be pumped or driven into a second chambercontaining chemicals, beads or solutions containing chemicals or beads.The second chamber may contain rotors or stir bars that may be driven bymagnetic or mechanical means by the operating machine in order toenhance or control mixing.

In still another application, the unitary particle processing cartridge100 may perform size-based filtering of particles, such as cells. Forexample, a cell suspension in a first chamber of the cartridge may bepumped into a second chamber through a filter, which permits only cellsor particles below a certain size to flow into the second chamber. Thisoperation produces a size defined sub-population of cells in the secondchamber.

In another application, the unitary particle processing cartridge 100may perform magnetic bead cell subset depletion or enhancement. Forexample, a cell suspension in a first chamber in the cartridge may bepumped into a second chamber containing magnetic beads coated withanti-CD4 antibodies, so that cells expressing CD4 on their surface willbind to the beads. After mixing in the second chamber, a magnetic fieldis applied by an external operating machine to the second chamber in theunitary particle processing cartridge. The magnetic field precipitatesthe beads, and any cells bound to the bead, to the wall of the secondchamber. Then, the liquid and remaining cells in suspension are pumpedinto a third chamber in the cartridge, which then contains a populationthat is depleted for cells expressing CD4. A liquid may be then added tothe second chamber to release the magnet, thus allowing the bead-boundcells to go back into suspension (with the beads). After suspension ofthe bead-bound cells, the resulting suspension may be pumped into afourth chamber on the cartridge, which will then contain a population ofcells enhanced for those expressing CD4.

One skilled in the art will recognize that the invention is not limitedto magnetic bead cell subset depletion or enhancement, but can encompassany suitable process for depleting or enhancing bead cell subsets. Forexample, in one application of the unitary particle processingcartridge, a cell suspension in a first chamber may be pumped into asecond chamber containing large latex beads, preferably more than 50microns diameter, that are coated with anti-CD4 antibodies, so thatcells expressing CD4 on their surface will bind to the beads. Aftermixing of the cell suspension and the beads in the second chamber, theresulting suspension is pumped into a third chamber through a sizeseparation filter that allows particles smaller than 40 microns to passand recycles larger clumps into the second chamber. The third chamberthen contains a population that is depleted for cells expressing CD4. Ifliquid containing a chemical or enzyme that breaks the binding betweenthe beads and the anti-CD4 antibodies is then added to the secondchamber, the bound cells can be re-suspended and that suspension may bepumped into a fourth chamber which will then contain a population ofcells enhanced for those expressing CD4.

According to still another application, a unitary particle processingcartridge 100 may be used to perform release testing of a product orsubstance. For example, a filter in the cartridge may trap a product orsubstance of interest, such as bacteria, in a sample that flows throughthe filter. The trapped bacteria may then be collected from the filterfor testing.

The unitary particle processing cartridge 100 may include a plurality ofsample processing subsystems 110 in the cartridge. For example, two ormore sample processing subsystems 110 may be disposed in series on thecartridge to allow sequential processing of a sample. An enrichmentregion between the serial processing subsystems may allow for resettingof sample parameters between processes. An example of a suitableenrichment region between two sample processing stages 110 is found inU.S. application Ser. No. 10/329,008, the contents of which are hereinincorporated by reference. For example, the enrichment region may beformed by a filter disposed between the sample processing subsystems onthe cartridge.

According to another embodiment, a unitary particle processing cartridgemay be used for particle sorting. The illustrative cartridge 200performs cell sorting, though one skilled in the art will recognize thatthe cartridge 200 may perform sorting on any type of particle. FIG. 3illustrates a unitary particle sorting cartridge 200 including amicrofluidic based sorting component 120 for sorting particles withoutan aerosol phase according to an illustrative embodiment of theinvention. Upstream of the sorting component 120, the cartridge 200includes a cell source 112 for storing particles to be sorted, a sheathfluid source 114 storing a sheath fluid for facilitating a sortingprocess, a sterile filtered pneumatic port 101 for the cell source, asample loading port 102 for the cell source, a sterile filteredpneumatic port 103 for the sheath fluid and a fluid loading port 104 forthe sheath fluid reservoir 114. The pneumatic ports 101, 103 applypressure to induce or facilitate fluid flow through the cartridge.Channels, illustrated as tubes 116 and 118, connect the cell source 112and sheath fluid reservoir 114, respectively, to inlets of the sortingcomponent 120. Downstream of the sorting component 120, the cartridgeincludes keep chambers 124 a, 124 for collecting sorted particles, tubes126, 128 connecting the outlets of the sorting component 120 to the keepchambers 124 a, 124 b. The cartridge also includes an extraction port106, 108 for each keep chamber 124 a, 124 b, respectively, forextracting collected fluid from each keep chamber, and sterile fluidpneumatic ports 105, 107, respectively. The cartridge processesrelatively large volumes (0.1 ml to 5000 ml of suspension) and equal orlarger volumes of sheath fluid through the system and out into outputchambers 124 a, 124 b.

The sorting component 120 can be any suitable device for sortingparticles based on a predetermined characteristic. Examples of asuitable cell sorting device include a microfluidic sorting chip, asdescribed in U.S. Pat. No. 6,808,075 and U.S. patent application Ser.Nos. 10/329,008 and 10/664,587, the contents of which are hereinincorporated by reference. However, the invention is not limited to useof a cell sorting component described in these references.

The sorting component 120 may be separately manufactured, stored, and/orshipped, and subsequently inserted into the cartridge substrate 200,creating a flexible connection. Alternatively, the sorting component 120may be integrally and rigidly formed on the cartridge substrate 200.

As shown, fluidic connections from the cell source 112 or sheathreservoir 114 to the sorting component 120 and from the sortingcomponent to the keep chambers 124 a, 124 b, can be made with singletubes or arrays of tubes. The tubes creating the fluid paths can be ofany appropriate diameter.

An embodiment of a unitary particle processing cartridge of the presentinvention, such as the unitary particle processing cartridge 100 shownin FIG. 2 or the unitary particle sorting cartridge 200 of FIG. 3 hasseveral properties that are improvements in operation of a cell orparticle sorting system. For example, most, and preferably all, of thefluid contact surfaces are built into one object (“the cartridge”). Theunitary cartridge including all the fluid contact surfaces can beinserted into a processing instrument (the platform containing sortingoptics, electronics, control software and other subsystems thesuspension never contacts) with a single operation. The unitarycartridge can also be disposed of in a single operation after use. Thecartridge can be sterilized after assembly all at once. The cartridgecan be shipped to the user in a sterile, ready to use form. Eachcartridge (and therefore all fluid contact surfaces needed for a singleprocessing run) can be given a barcode or other unique identification,making all of the parts that represent possible sources of productcontamination fully traceable. In addition, no fluid waste needs to beremoved from the cartridge in operation. Rather, fluid waste can bedisposed of with the disposal of the cartridge, without requiringseparate handling of the fluid waste.

Use of a unitary particle processing cartridge of the present inventioncan enhance operator and product isolation. To use the cartridge toperform a particle processing operation, such as particle sorting, auser can receive the cartridge sealed and sterile from the manufacturer.The user may then take a cartridge to a biosafety hood, such as asterile laminar flow hood, and perform a sterile operation (in themanner of conventional tissue culture for that type of sample) to loadcell sample and sheath reservoirs. The cartridge is preferably sealedbefore and after this operation. The user places the cartridge in thesorting instrument platform. The system sorts the cells or particles inthe sample into one or more of the keep chambers in the cartridge. Theuser removes the cartridge from the system and takes the cartridge backto the biosafety hood to remove the processed samples through theirextraction ports. The user may then dispose of the used cartridge andunneeded fluids in a safe manner. Similar steps may be taken to performother processes on a sample using a unitary particle processingcartridge.

As shown in FIG. 4, a unitary particle processing cartridge 100′ of anembodiment of the invention may include also an aggregation filter 180to help remove clumps of cells and prevent clogging of the sortingcomponent. As shown, the aggregation filter 180 can be added to thefluid line(s) 116 connecting the cell source 112 to the processingcomponent 110. The aggregation filter 180 may comprise any suitablematerial suitable for filtering a sample and may be disposed in anylocation along a fluid flow path in the cartridge 100′.

As shown in FIG. 5, a unitary particle processing cartridge 100″ ofanother embodiment of the invention may include a component for liquidlevel/concentration control and sheath recycling after performingparticle processing using the processing component 110. The illustrativecartridge 100″ includes a pump 192, 194 and a filter 182, 184 downstreamof each processed particle chamber 124 a, 124 b, respectively, thatreceives processed particles from the processing component. The pumps192 and 194 and filters 182, 184 facilitate liquid level/concentrationcontrol and recycling of a processing means, such as sheath fluid, usedto process the particles. The filters 182, 184 maybe three-port flowfilters, for example, hollow fiber filters, for removing fluid, such assheath fluid, from a fluid path (i.e., the corresponding processedparticle chamber 124). The system thus removes sheath fluid from theprocessed particle chambers to raise the concentration of collectedparticles in the processed particle chambers and to control the level ofliquid in each processed particle chamber 124 a, 124 b.

The illustrative unitary particle processing cartridge 100″ alsoincludes a recycling component for recycling fluid collected by thefilters 182, 184. As shown, the excess fluid may be recovered (recycled)and returned into the processing medium reservoir 114, for example, asheath fluid reservoir, using a recycling path 1121, recycling reservoir191 and a pump 190. The recycling reservoir 191 receives the removedfluid from the filters 182 and 184, and the pump 190 returns theextracted fluid from the filters 182 and 184 to the chamber 114 viafluid path 1121 for reuse during subsequent particle processingprocedures.

FIGS. 6A-6D are CAD drawings of an embodiment of unitary particleprocessing cartridge 200 for particle sorting. Each cartridge is formedby a reservoir tray 151 and a reservoir cover 152. A pressure system 153includes pressure inlets 155, 156 for applying a pressure to inducefluid flow through the fluid paths. A pumping system 154 alsofacilitates fluid flow and includes pump heads 158, 159. A filter 157 inthe fluid path upstream of the sorting component 120 helps preventclogs. Concentrating filters 182, 184 downstream of the keep chambershelp control fluid concentration levels and facilitate recycling ofsheath fluid. Valves 191, 192, 193 and 194, which may be luer-activated,interface with the cell source, sheath reservoir and keep chambers toinject or remove fluid from the cartridge. Vents 187, 188 may also beprovided. As shown, the cartridge 200 has a holder 122 forms a shapedregion or recess for receiving a processing component, illustrated as asorting component 120, such as the sorting chips described in U.S. Pat.No. 6,808,075 and U.S. patent application Ser. Nos. 10/329,008 and10/664,587, which are incorporated herein by reference. The invention isnot limited to the sorting chips or processes described in thesereferences.

As shown in FIG. 7, a unitary particle processing cartridge 1100 ofstill another embodiment of the invention may include a trap filter 1120for filtering a recycling line 1121 from a recycle reservoir 191.Preferably, the trap filter 1120 is selected to remove selectedparticles or molecules from the recycle line 1121.

The trapping filter 1120 may be removable from the cartridge 1100 toallow for further analysis of components trapped thereon. For example,in a cartridge that processes cells, the recycle reservoir 191 mayreceive supernatant pulled off of particles stored a processed particlechamber 124 by the filter 182 or 184. In one application, a steriletrapping filter, such as a 0.2 micron filter, may be used to trapmicrobes in the fluid in the recycling line 1121. The sterile trappingfilter can subsequently be removed from the cartridge for microbialtesting. In this manner, testing is more accurate and reflects a largerfraction of microbes present in a sample.

A sterile trapping filter may also be used to perform molecular cleaningof a sample flowing through the trapping filter 1120.

The trapping filter 1120 may alternatively comprise a plurality of beadsfor trapping certain components in the sample.

FIG. 8 illustrates another embodiment of components of a unitaryparticle processing cartridge 2100 for processing cells according to theinvention, including a pump-based supernatant recycling component. Inthe embodiment of FIG. 8, a simple supernatant recycling system uses ahollow core filter 1820 and two peristaltic pumps 1900, 1920. Cellspassing through the cell processing system 110 emerge into the processedsample chamber 124 a. Liquid containing cells is pumped through the coreof the hollow core filter 1820 and back into the processed samplechamber 124 a. Liquid, but no cells, can pass through the walls of thefilter 1820 so liquid without cells is driven into the recycle reservoir191. Preferably, the recycle reservoir 191 is maintained at atmosphericpressure using a gas pressure port 107, and the pump 1900 drives liquid(now without cells) into the sheath fluid reservoir 114 for re-use. Thesheath fluid is driven by a regulated gas pressure into the cellprocessing system.

In the illustrative embodiment, the pressure of the unitary particleprocessing cartridge 2100 system Ps is relatively high, in order todrive sheath into the cell processing unit. The pressure of gas pressureports 103, 105, which vent the processed sample chamber 124 a and therecycle reservoir 191, respectively, are both regulated to atmosphericpressure.

According to another embodiment, shown in FIG. 9, a unitary particleprocessing cartridge 3100 including a pump-based supernatant recyclingcomponent may also include a trap filter 3180. In one embodiment, thetrap filter 3180 may comprise a 0.2 um sterile mesh capable of trappingviruses and microbes. In that case as one cycles the system, a higherand higher percentage of liquid passes through that trap filter 3180,which collects a percentage of any microbes present in the initial cellsource or sheath fluid.

Alternatively or at the same time, the trap filter 3180 used in aunitary particle processing cartridge may have molecular retentionproperties. For example, the trap filter may contain beads coated withprotein G and protein A that bind immunoglobulins in the liquid that thesystem drives through the trap filter 3180. In such an embodiment, thecycling system “cleans” the liquid of any molecule which can be trappedby appropriate affinity binding beads.

A unitary particle processing cartridge employing such a trap filter maybe used in several ways. For example, if the cell processing unit 110 isa simple mixing chamber and the initial sheath fluid contains anti-CD4mouse antibody linked to a FITC fluorophore, the trap may containbead-bound anti-mouse antibody and a 0.2 um filter to retain the beads.In such an embodiment, the system stains the input cells with theanti-CD4 antibody and then washes the stained cells to remove unboundantibody.

In another application, the trap filter 3180 may comprise a 0.2 umsterile filter made as a removable volume of about one milliliter. Thetrap filter traps any microbes in the original cell volume aftersufficient cycling. From the point of detecting microbes in a batch ofhuman cells in order to release the cells for use in cell therapy (bonemarrow transplantation), a liter of cells may be used to thenconcentrate all the microbes into the one milliliter in the trap filter,allowing enhanced the concentration of any microbes by 1000×. Such amethod makes conventional microbe detection assays much more rapid.

According to still another embodiment of the invention, shown in FIG.10, a unitary particle processing cartridge 4100 may include a pneumaticsupernatant recycling system using a hollow core filter 4180 and nopumps. This subsystem of a cartridge has five chambers: a firstprocessed sample chamber 124 a (keep1), a second processed samplechamber 124 c (keep2) coupled to the first processed sample chamber 124a via fluid path 4182, a first recycle chamber 4191 (recycle1), a secondrecycle chamber 4192 (recycle2), and a sheath chamber (sheath) 114.

All chambers are preferably at controlled pressures at all times. Thepressures may be controlled using gas pressure ports 4101, 4102, 4103,4104, 4105 and 4106 connected to the sheath chamber 114, the cellprocessing unit 110, the first processed sample chamber 124 a, thesecond processed sample chamber 124 c, the first recycle chamber 4191and the second recycle chamber 4192, respectively. By controlling theflow resistances of the fluid paths (i.e., the tubing) between thechambers, the flow rate is therefore controlled. The cell processingunit 110 is maintained at an output pressure of Pc. The first processedsample chamber 124 a is at a pressure of Pk1 which is below Pc.

The unitary particle processing cartridge 4100 has two flow states forthe first processed sample chamber 124 a, the second processed samplechamber 124 b and the first recycle chamber 4191. In the first state,the pressure Pk1 of the first processed sample chamber is at a firstlevel that is greater than the pressure Pk2 of the second processedsample chamber 124 c and the pressure Pr1 of the first recycle chamber4191, which are both zero. In a second state, the pressure Pk2 of thesecond processed sample chamber 124 c is at a third level that isgreater than the pressure Pk1 of the first processed sample chamber Pr1and the pressure Pk2 of the first recycle chamber, which are bothgreater than zero.

In the first state, a sample comprising liquid containing cells flowsfrom the first processed sample chamber 124 a to the second processedsample chamber 124 c through the core of the filter 4180. Supernatantfrom the sample flows through the wall of the filter 4180 into the firstrecycling chamber 4191.

In the second state, a sample comprising liquid containing cells flowsfrom the second processed sample chamber 124 c to the first processedsample chamber 124 a and supernatant also flows through the wall of thefilter into the first recycling chamber 4191.

In both states, the supernatant preferably has the same flow rate intothe first recycling chamber 4191.

A control system, which is located off of the cartridge 4110, controlsthe pressures in the cartridge to oscillate between the first state andthe second state in order to prevent the first or second processedsample chamber from either overflowing or draining.

The second recycle chamber 4192 is maintained at a pressure below thefirst recycling chamber 4191 until it is full, and is then switched to apressure higher than both the first recycle chamber 4191 and sheathfluid chamber 114 in order to drive all liquid from the recycle chamberinto the sheath fluid chamber 114. Then, the second recycling chamber4192 is brought back to a pressure below the first recycling chamber4191 to refill, and the sheath injection cycle repeats. Preferably,check valves 4195, 41976 are in place in the fluid paths between thefirst recycling chamber 4191, the second recycling chamber 4192 and thesheath fluid chamber 4114 to prevent backflow.

This system 4110 has few or no contact surfaces (i.e., peristaltic orother mechanical pumps) which may damage cells and so can improve yieldsof live cells.

FIGS. 11A-11C illustrate a suitable application of the unitary particleprocessing cartridge of the illustrative embodiment of the invention. Inthe embodiment of FIGS. 11A-11C, a unitary cartridge 100 is integratedwith a multiwell plate. FIG. 11A is a cross-sectional view of thecartridge, with chambers in a rigid body and a chip 1100 connected tothe cartridge 100 through flexible tubes. The chip 1100 is stored forshipping and handling in a rigid “chip-receptacle” 1110 on the cartridge100. The chip receptacle 1110 is sized and configured to receive andcouple the chip 1100 to the cartridge.

In the illustrative embodiment, the chip 1100 may be a microfabricatedglass chip as described in U.S. Pat. No. 6,808,075 and U.S. patentapplication Ser. Nos. 10/329,008 and 10/664,587, or a combination of amicrofabricated chip in a non-microfabricated plastic package (chipholder) which are together stored in a rigid chip receptacle and slideout of that receptacle into the “Operating machine” for operation. Thechip then moves back into the receptacle 1110 when the cell processingis done and the cartridge is removed for product extraction anddisposal.

FIG. 11B shows an embodiment in which the chip 1100 has multiple inputtubes 1122 a-e. A well multi-well plate 1140, illustrated as containingfour wells, though more or less may be used, is placed or connected tothe cell input chamber in the cartridge, so that each tube receivescells from a different well of the multi-well plate 1140. In thisembodiment, a pressure sealing plate 1150 may be used to seal the wholechamber so that a single driving pneumatic pressure is capable ofdriving multiple wells at once.

Alternatively, a sealing plate 1150′ may be placed over the top of thewells of a multi-well plate, so that each well can be separately driven,as shown in FIG. 11C.

According to one embodiment, a multi-well plate may be clamped to aunitary particle processing cartridge so that each cell access tube 1122is separately sealed onto each well, and the pressure in each well canbe separately controlled. The system may include separate pneumaticcontrol tubes to provide such separate control.

Multiwell variant cartridges are also very appropriate where a unitprocess in the cartridge is implemented with a chip that hasparallelism. For example if the chip is an optical microsorter array of96 microsorters, the system may route one microsorter to one well in a96 well plate.

FIGS. 12A-12D are photographs of a prototype of a unitary particleprocessing cartridge of an illustrative embodiment of the invention. Asshown in FIGS. 12A and 12B, a processing chip 1100 and a chip holder1110 may be connected to a multi-chamber cartridge body 100 usingflexible tubes 1122.

FIG. 13 illustrates another application of a unitary particle processingcartridge for processing particles. In the embodiment of FIG. 13, thecartridge system 1300 allows for aggregation of a processed sampleoff-chip. The illustrative chip 1310 contains an array of microchannelsof a width scale of between about 10 μm and 400 μm. The chip holder 1340for coupling the chip to the cartridge 1300 preferably contains chambersand tubes of a width scale of between about 100 μm to about 2millimeters. The cartridge 1300 contains tubes of a width scale ofbetween about 0.5 mm and about 10 mm and chambers of a volume scale ofbetween about 1 millimeter and about 5000 millimeters.

FIG. 13 shows a cutaway portion of one channel 1322 of the chip 1310 forpurposes of illustration only.

The chip holder 1340 includes aggregating chambers or channels 1345 forreceiving a processed sample or input sample. The aggregating chambers1345 connect to fluid paths, illustrated as flexible tubes 1360,preferably of equivalent or larger scale, which in turn feed to chambers1334 in the cartridge 1300. Preferably, the chambers 1334 have volumesof between about 1 milliliter and about 5000 milliliters.

Alternatively, chambers on the chip holder 1340 may connect a channel onthe chip 1310 to a chamber on the chip holder 1340, which then connectsto a flexible tube or other fluid path. A plurality of the flexibletubes then aggregate into chambers in the cartridge.

The embodiment of FIG. 13 thus provides aggregation of separatelyprocessed, parallelized samples in a manner that reduces clogging.

In general, a unitary particle processing cartridge of an illustrativeembodiment of the invention is a single object sealed against liquidtransfer either in or out of the cartridge, except at specific portsthat are only used in a specific standard operating procedure (SOP) thatguarantees that their use does not violate the isolation of the interiorof the cartridge or leak interior samples into the exterior.

In one embodiment, the unitary particle processing cartridge is operatedby being placed in a machine or system (the “Operating Machine”) whichmay apply means of actuation and sensing to the cartridge to perform oneor more “unit process operations” on a suspension that has been loadedinto the cartridge. The unit process operations performed using thecartridge may change the state of the suspension, measure someproperties of the suspension, both change the state and measuresselected properties of a suspension, or other perform another suitableprocess on a suspension loaded in the cartridge. Examples of unitprocesses suitable for use with the unitary cartridge of an illustrativeembodiment of the invention include, but are not limited to, measuringthe number of cells in a suspension, measuring the amount of liquid in asuspension, measuring the type of cells in a suspension, which may be acytometry operation, sorting cells in the suspension, collecting asubset of the cells in a suspension, heating the cells in a suspension,filtering a suspension to increase the concentration of cells therein,and changing the liquid or its chemical components in a suspension.

The operating machine that operates on the unitary particle processingcartridge may use electrical, mechanical, pneumatic, optical, magneticor other suitable actuation or sensing means known in the art to performunit process operations on a suspension in the cartridge. Examples ofactuation or sensing means suitable for use in an operating machine thatemploys the unitary cartridge of the illustrative embodiment of theinvention include, but are not limited to, pneumatic means, mechanicalmeans, optical means, magnetic means and electrical means. To actuate orsense using a pneumatic means, a gas may be injected through a sterilefilter to drive a liquid suspension from one chamber to another or froma chamber through a component such as a size filter and into a secondchamber. To actuate or sense using a mechanical means, a peristalticpump head may be built into the cartridge so that an external rotor mayfit into that head and by rotating it pump liquid or gas from onechamber to another. To actuate or sense using an optical means, a lightbeam may be disposed relative to the cartridge to pass through amicrochannel in the cartridge in order to count cells or particles thatpass through that microchannel and transiently block or scatter thelight on its way to a photodetector. To actuate or sense using amagnetic means, a rotating magnet may be brought close to a chambercontaining a conventional magnetic stir bar, causing that stir bar torotate and stir or mix the suspension in that chamber. To actuate orsense using an electrical means, conventional silicon pressure ortemperature sensors may be built into the cartridge and their electricalleads may be connected to through the means of external contact pins.The operating machine may then apply and read voltages to or from thesecontact pins to operate the sensors. Alternatively, using an electricalmeans, a data storage means, which may be part of a microcontroller orCPU, digital or analog, may be built into the cartridge if it isadvisable for the cartridge itself to be given a logging function orintelligence function to support its use or standard operatingprocedures for handling the cartridge. Power for these devices may comefrom the operating machine or be derived from batteries or electricalpower storage means located within the unitary cartridge. In anotherembodiment of a mechanical means for performing a process in asuspension loaded in a cartridge, two chambers may be connected by atube with a region containing a soft wall to form a valve. Then, theoperating machine may press on this region with a mechanical plate orother suitable means to temporarily or permanently crimp that region andselectively block liquid or gas flow from one chamber to another.

The use of the cartridge allows the operating machine to be isolatedfrom and external to the processing subsystem and fluid contact surface.In this manner, the operating machine can be used repeatedly, while thefluid contact surfaces can be disposable.

The present invention enables customization of a unitary cartridge tooptimize a cartridge for any given cell processing protocol byengineering into the cartridge only the required unit processes.

Chemical reagents, beads and/or particles that are either specific tothe cell or particle processing protocol or independent of the protocolcan be stored and shipped within the cartridge for processing by theuser. Alternatively, the substances used in the selected process may beshipped separate from the cartridge and inserted in the cartridge by atechnician at an intermediate stage, or a final user at an end stage.

The present invention has been described relative to an illustrativeembodiment. Since certain changes may be made in the above constructionswithout departing from the scope of the invention, it is intended thatall matter contained in the above description or shown in theaccompanying drawings be interpreted as illustrative and not in alimiting sense.

It is also to be understood that the following claims are to cover allgeneric and specific features of the invention described herein, and allstatements of the scope of the invention which, as a matter of language,might be said to fall therebetween.

The invention claimed is:
 1. A particle processing system, comprising: aunitary cartridge including: a particle processing component having oneor more microchannels and configured to receive a light beam into theone or more microchannels to detect individual particles flowing throughthe one or more microchannels; and one or more fluid chambers, each ofthe fluid chambers including one or more fluid contact surfaces that areconfigured to be encapsulated and sealed within the cartridge from anexterior environment during a particle processing operation, the one ormore fluid chambers in fluid communication with the one or moremicrochannels of the particle processing component to provide fluid toand to receive fluid from the particle processing component.
 2. Theparticle processing system of claim 1, wherein the particle processingcomponent is configured to sort particles suspended in a sample fluidflowing through the one or more microchannels.
 3. The particleprocessing system of claim 1, wherein the unitary cartridge includes arecess configured to receive the particle processing component andconfigured to fluidically couple the particle processing component tothe fluid chambers.
 4. The particle processing system of claim 1,wherein the particle processing component is formed separately from theunitary cartridge and then subsequently placed in fluid communicationwith the fluid chambers of the unitary cartridge.
 5. The particleprocessing system of claim 1, wherein the one or more fluid chambersinclude a particle or cell source chamber and a sheath fluid reservoirupstream of the particle processing component and a keep chamber and abyproduct chamber downstream of the particle processing component. 6.The particle processing system of claim 1, wherein the unitary cartridgeincludes a sealable sample extraction port for extracting a processedsample from the unitary cartridge.
 7. The particle processing system ofclaim 1, wherein the unitary cartridge comprises a plurality of particleprocessing components.
 8. The particle processing system of claim 1,wherein the particle processing component includes a plurality ofparallel processing microchannels.
 9. The particle processing system ofclaim 1, wherein the unitary cartridge includes a unique identifier. 10.The particle processing system of claim 9, wherein the unique identifieris a barcode.
 11. The particle processing system of claim 1, wherein theunitary cartridge interfaces with an instrument having sorting optics.12. The particle processing system of claim 1, wherein the unitarycartridge interfaces with an instrument which actuates a particlesorting operation.
 13. The particle processing system of claim 1,wherein the unitary cartridge interfaces with an instrument and theinstrument is fluidically isolated from the unitary cartridge.
 14. Theparticle processing system of claim 1, wherein the unitary cartridgefurther comprises a return flow path fluidically couplable between theone or more fluid contact surfaces and an input to the particleprocessing component for introducing a portion or component of ananalyzed or processed sample as an input to the particle processingcomponent.
 15. The particle processing system of claim 1, wherein theparticle processing component is positioned and adapted to transmit thelight beam to a photodetector to sort the individual particles having apredetermined characteristic from the individual particles that do nothave the predetermined characteristic.
 16. The particle processingsystem of claim 1, wherein the unitary cartridge is configured fordisposal after a single use.
 17. The particle processing system of claim1, wherein one or more of the one or more microchannels includes anaggregation filter.
 18. The particle processing system of claim 1,wherein the unitary cartridge further comprises a concentration filterdownstream of at least one of the one or more fluid chambers.
 19. Theparticle processing system of claim 1, wherein at least one of the oneor more fluid chambers includes a mechanical or magnetic stirrer. 20.The particle processing system of claim 1, wherein the one or more fluidchambers include a cell source chamber that is fluidically coupled to asealable valve.